Surface pile fabric and its method of manufacture

ABSTRACT

AN IMPROVED SURFACE PILE FABRIC WHICH IS COMPRISED OF A BASE FABRIC AND PILE FIBERS INTERTWINED WITH THE BASE FABRIC AND EXTENDING THEREFROM TO PROVIDE A PILE WHICH HAS BEEN IRREGULARLY DISORIENTED INTO AN IMPROVED SURFACE PATTERN AS A RESULT OF THE RELAXATION OF STRESSES IN FIBERS UNDER THE IMPINGEMENT OF HEAT AND FLUID PRESSURE FOR A GIVEN PERIOD OF TIME. THE METHOD OF MANUFACTURE OF THIS IMPROVED SURFACE FABRIC IS SUCH THAT THE PILE FIBERS MAY ALL HAVE SUBSTANTIALLY THE SAME DISORIENTATION CHARACTERISTICS.

June 15, 1971 w. R. TRUSCOTT ET AL 3,585,098

SURFACE PILE FABRIC AND ITS METHOD OF MANUFACTURE Filed Aug. 29, 1967 Innn, pm,, 11111,, "#0 Il 0 United States Patent 3,585,098 SURFACE PILEFABRIC AND ITS METHOD OF MANUFACTURE Wayne R. Truscott, Delavan, andHarry A. Freedman,

Beloit, Wis., assignors to The Bunker-Ramo Corporation, Oak Brook, Ill.

Filed Aug. 29, 1967, Ser. No. 664,017 Int. Cl. D03d 27/00 US. Cl. 161636 Claims ABSTRACT OF THE DISCLOSURE An improved surface pile fabricwhich is comprised of a base fabric and pile fibers intertwined with thebase fabric and extending therefrom to provide a pile which has beenirregularly disoriented into an improved surface pattern as a result ofthe relaxation of stresses in the fibers under the impingement of heatand fluid pressure for a given period of time. The method of manufactureof this improved surface fabric is such that the pile fibers may allhave substantially the same disorientation characteristics.

SUMMARY OF THE INVENTION This invention relates to pile fabrics and,more particularly, it relates to a pile fabric having an improvedsurface pattern resulting from the disorientation of the fibers causedby the relaxing of stresses in the fibers under the impingement of heatand fluid pressure for a given period of time.

Several different methods have been used to obtain a patterned surfacein pile fabrics. One such method incorporates a pressing roll with thedesired pattern formed as a raised portion on the surface of the roll.The pile fabric is pressed by the roll in the presence of heat so thatthe uniform pattern is pressed into the pile fabric. In this operation,the particular design on the pressing roll is repeated over and overagain on the surface of the pile fabric.

Other patterned effects have been accomplished by the selection anddispersion of synthetic fibers of different denier, length, andshrinkage. In these methods the varying characteristics of the varyingfibers result in groups of fibers with varying lengths therebyproducing, a random pattern effect in the surface of the pile fabric.These methods, involving the use of varying characteristic fibers,result in an involved process of intertwining the pile fibers with thebase fabric in a given pattern, thus complicating the knittingoperation.

The improved surface pattern pile fabric of the subject invention isattained without the use of a uniform pattern pressing roll and withoutthe specific selection and dispersion of special synthetic fibers anddepending on these fibers to obtain a predetermined pattern. Theresulting pattern of the subject invention is in contrast to thepatterns of the methods commonly used in that the resulting pattern isnot uniform and is not one that can be predetermined. Hence, eachpattern produced by the process of this invention is unique and unlikeany other pattern produced thereby. The resulting pattern in thisapplication can best be described as being similar to a bark effect asappears on the surface of a tree. Even though the bark effect isachieved over and over again, there is no degree of mechanicalrepetition in the non-uniform, irregular surface resulting from thepresent method. The previously known methods rely primarily on theshrinkage of the fibers to produce the pattern effect. In contrast, thesubject method is not one in which shrinkage plays a role in theproduction of the surface pattern, rather, it is the result of therelaxation of the inherent fiber stresses and the 3,585,098 PatentedJune 15, 1971 disorientation and curling of the fibers which producesthe effect.

Hence, the subject pile fabric can be manufactured from fibers of onetype or a mixture of fibers or different types without affecting theresultant pile surface as the subject method does not rely upon varyingcharacteristics of different types of fibers, but rather relies upon therelaxation of the inherent stresses in the fibers, regardless of thetype of fiber.

DESCRIPTION OF THE DRAWINGS To understand more fully the details of thisinvention reference may be had to the drawings, wherein:

FIG. 1 is a schematic perspective view of a length of pile fabric and aheat and fluid dispensing oven through which the pile fabric passes;

FIG. 2 is an enlarged view of the pile fabric prior to passage throughthe oven; and

FIG. 3 is an enlarged View of the pile fabric including the improvedsurface pattern after it has been treated in the oven.

DETAILED DESCRIPTION More specifically, the drawings show a length ofpile fabric 10 which is comprised of a base fabric 12 and a plurality ofindividual pile fibers 14. As in most pile fabrics the pile fibers 14are intertwined with the base fabric 12 and extend upwardly therefrom soas to produce a uniform pile fabric surface 16. The pile fabric in thisparticular instance can be manufactured from acrylic, modacrylics,polyesters, and blends of these fibers or other synthetic textileswhich, under the influence of heat, are able to be softened. As in theproduction of most pile fabrics, the upper surface 16 has been shearedso as to result in a uniform, smooth surface.

Oven 18 in FIG. 1 may be of a standard type used to heat set the basefabric of a pile fabric. In such a standard, heat set operation the pilefabric is passed through the oven 18 with the base fabric 12 facingupward so that the pile fibers and the base fabric become heat settogether. The oven 18 contains apparatus capable of heating the fabricto predetermined temperatures as it passes through the oven. The ovenalso includes apparatus to impinge a fluid stream, such as hot air ordry steam, onto the surface of the pile fabric. This stream of fluid ispassed from the oven 18 through one of a series of bafiles 20 and ontothe pile surface of the pile fabric. It should be noted that the fluidimpings onto the pile surface over its full width and not just selectedareas.

'In order to accomplish the purpose of the present invention, the pilefabric 10 is fed through the oven 18 with its pile fiber surface 16facing upwardly as viewed in FIG. 1. As the pile surface is fed into theoven 18 it is softened by the heat of the impinging fluid and it is atthis point that the pattern or bark effect begins to form on the surfaceof the pile fabric. When the individual fibers 14 are softened, there isa relaxation of the normal fiber stresses which were introduced duringthe fiber production, and once the fibers become relaxed, they areeasily disoriented and curled by the force of the impinging fluid. Theresulting positioning of the fibers can be seen in FIG. 3 where thefibers 14 have become curled and intertwined with each other in anirregular surface pattern 22. Once the fiber has been allowed to cool itremains in its disoriented and curled position with stability to bothlaundering and dry cleaning.

As previously mentioned, it is necessary to direct a fluid such as hotair or dry steam onto the pile surface. The relationship of time,temperature, and force of the impinging fluid are important with respectto the degree of permanency of the bark effect on the surface of thepile. The best results have been achieved when heat is applied so as toraise the temperatures to between 325 F. and 350 F., depending upon thefiber type; with a fluid pressure in the impinging fluid of A watergauge for three minutes exposure time. These conditions of time,temperature, and force of the impinging fluid have been found to be verysuccessful with a pile fabric having a fiber pile height ofapproximately However, it is possible to go slightly higher or lower inpile height. The pile density plays an important role in the creation ofthe bark effect with optimum conditions being from 7 to 12 oz. pile per60" linear yard of pile fabric. Any increase in pile density over the 12oz. per 60" linear yard will not allow the fibers to curl as readily dueto the greater fiber population in the given area. Any less than 7 oz.per 60" linear yard will produce a fabric which has openings throughwhich the base fabric or backing can be seen, which is undesirable froman appearance standpoint. The finish on the fabric prior to producingthe bark effect is also important. The pile surface should have gooddirectional lay with good fiber freeness and the depth of finish shouldbe high; thereby adding to the fiber freeness.

Therefore, it should be clear that the subject invention provides a newmethod of treating pile fabrics so as to result in an improved surfacepattern on a pile fabric which produces a bark effect on the surface ofthe pile fabric. Such resulting pile fabrics containing the bark effectsurface finish have many commercial uses including mens and womens outergarments, linings for outer garments, and unique floor and furniturecoverings.

Although but one specific impingement of this invention has beendescribed in detail, it should be clear to those skilled in the arts towhich it pertains that many changes and modifications may be madethereto without departing from the scope of the invention as set forthin the appended claims.

We claim:

1. The method of producing an improved random nonrepetitive patternfabric which consists of knitting a backing and simultaneouslyintertwining therein multiple heatsoftenable synthetic face fibersprojecting from one surface thereof in a generally straight pattern,shearing the fibers to render the length thereof generally uniform andthereafter subjecting all of the sheared fabric to a series ofimpingements of fluid streams in the presence of an amount of heatsuflicient to soften the fiber, whereby the fibers are caused to relaxtheir internal stresses and under the influence of the fluid assumerandom non-repetitive patterns giving an overall irregularnon-repetitive pattern.

2. The method of claim 1 wherein the heat is in the range of from 325 F.to 350 F.

3. The method of claim 1 wherein the face fibers consist of fibershaving the same chemical composition.

4. The product produced by the method of claim 1.

5. The method of claim 1 wherein the pile density of fibers is from 7 to12 ounces pile per inches linear yard of fabric.

6. The product produced by the method of claim 5.

References Cited UNITED STATES PATENTS 3,010,179 11/1961 Thal 2872FOREIGN PATENTS 745,070 10/1966 Canada 262 WILLIAM A. POWELL, PrimaryExaminer US. Cl. X.R.

